Blower motor for HVAC systems

ABSTRACT

A blower motor assembly having a variable speed motor that is suitable for replacing a PSC motor in a residential HVAC (heating, ventilation, and air conditioning) system. The blower motor assembly includes a variable speed motor and motor controller; a first power input for receiving a plurality of AC power signals from a control device for use in determining an operating parameter for the motor; and a second power input for receiving AC power from an AC power source for powering the motor controller even when no AC power signals are received by the first power input.

RELATED APPLICATIONS

The current patent application is a continuation patent application of anon-provisional patent application titled “BLOWER MOTOR FOR HVACSYSTEMS”, with application Ser. No. 14/977,371, filed Dec. 21, 2015,which is a continuation patent application of a non-provisional patentapplication titled “BLOWER MOTOR FOR HVAC SYSTEMS”, with applicationSer. No. 13/912,877, filed Jun. 7, 2013, which itself is a divisionalpatent application of a non-provisional patent application titled“BLOWER MOTOR FOR HVAC SYSTEMS”, with application Ser. No. 12/762,661,filed Apr. 19, 2010. The current application claims priority benefit ofall earlier-filed identified applications, and hereby incorporates theidentified applications by reference in their entireties into thecurrent application.

FIELD OF INVENTION

The present invention relates to blower motors and controls used inresidential heating, ventilation, and air conditioning (HVAC) systemsand other applications. More particularly, embodiments of the inventionrelate to a variable speed blower motor that may be used as areplacement for a permanent split capacitor (PSC) motor or in OriginalEquipment Manufacturer (OEM) applications and other applications.

BACKGROUND

HVAC system efficiency improvements have provided considerablereductions in energy use. For example, many high efficiency furnaces,air conditioners, and air handlers now have Annual Fuel UtilizationEfficiency (AFUE) ratings greater than 90%. However, many blower motorsused to move the air in these systems have not seen significantefficiency improvements and have much lower efficiencies. As furnacesand air conditioners have become more efficient, the fraction of totalenergy consumption attributed to blower motors has increased, thusmaking blower motors a greater contributor to overall HVAC system energyuse.

Blower motor inefficiencies are magnified when a blower motor isoperated for extended hours beyond that needed solely for heating andcooling. For example, some users choose to operate their blower motorcontinuously by setting a fan control switch to the “on” position. Thiscirculation mode of operation reduces temperature stratification,minimizes start drafts from duct work, improves humidity control, andincreases the effectiveness of associated air cleaners employed inconjunction with the HVAC system. By selecting the “on” position, theblower motor operates continuously, and the associated thermal feature,(i.e., either heating or cooling) operates on the “demand” setting ofthe thermostat. When in the “on” position, the blower motor typicallyoperates at the speed used for cooling, even when the thermostat is setto heat mode. This speed is usually well in excess of what is necessaryto achieve the air circulation benefits outlined above, causing excessenergy usage and noise. In addition, with the blower switch in the “on”position, the system can no longer select a speed for cooling or heatingand instead continuously runs at the continuous fan speed. Even whensystems are designed to select the proper speed in a multiple speedmotor, for example, as disclosed in U.S. Pat. No. 4,815,524, the speedavailable for blower “on” use is higher than necessary for suchoperations, and can be responsible for cold spot corrosion, requiring ashut down period disclosed in the '524 patent. The increased operationtime also leads to greater energy use.

Many of the above-described inefficiencies result from the type ofblower motor used in HVAC systems. HVAC systems traditionally use fixedspeed or multiple speed permanent split capacitor (PSC) motors. Thesemotors generally have two or more independent power connections toaccommodate two or more heating or cooling modes of operation. Theheating or cooling power inputs are normally connected to differentwinding taps in the PSC motor to provide somewhat different operatingspeeds for the blower in the respective modes of operation, allowing theOEM or installer to select the operating speed by appropriate connectionof the taps to the respective heating and cooling power connections. Theenergizing of these AC power connections to the motor is controlled byactivation of a temperature switch and a relay driven from thethermostat.

An example of a fixed speed PSC motor M used in residential HVAC systemsis shown in FIG. 1 and generally identified as 10A. The illustratedmotor has two winding taps to accommodate a heating fan speed and acooling fan speed. The fan speed is controlled by a furnace controlboard which receives control signals from a thermostat or other controldevice. Another exemplary PSC motor M is shown in FIG. 2 and generallyidentified as 10B. This motor has four winding taps to accommodate twoheating fan speeds and two cooling speeds. The fan speed is controlledby a furnace control board with a cool/heat relay, a low/high coolrelay, and a low/high heat relay. As with the motor shown in FIG. 1, thefurnace control board receives control signals from a thermostat orother control device. Other similar HVAC systems may include two heatingstages and a single cooling stage or any other combination of heatingand cooling speeds. The single phase AC supply voltage (normally 115 VACor 230 VAC) for both the motors of FIGS. 1 and 2 is supplied byconnections L1 and N, where L1 represents the hot side of the AC supply,and N is neutral, which is at earth potential in a typical 115 VACresidential distribution system. (In normal 230 VAC systems, another hotsupply line would be substituted for the neutral line N.)

PSC motors such as those shown in FIGS. 1 and 2 are reasonably efficientwhen operated at high speed, but their efficiencies may drop down intothe 20% range when operated at low speeds. Because air conditionerevaporator coils need higher airflow than furnace heat exchangers, theblower motor operates at a lower speed during furnace operation, whereit is less efficient, and at an even lower speed still during continuousfan “on” operation, where it is least efficient.

Because of the above-described inefficiencies of PSC motors, many newerHVAC systems use variable speed motors such as brushless permanentmagnet (BPM) motors and corresponding electronic variable speed motorcontrollers. The speed of a BPM can be electronically controlled and setspecifically to match the airflow requirements for each application,thus permitting more efficient operation. Also, BPM motors use powerapproximately proportional to the cube of motor speed, whereas PSCmotors use power approximately proportional to motor speed. Therefore,as motor speed drops, BPM motors use less power than PSC motors. This isparticularly important when operating the blower continuously forcirculation as described above.

While variable speed motors are often superior to PSC motors, replacingan existing PSC motor with a variable speed motor has required costly,time-consuming, and complex changes in the mechanical, wiring, orcontrol configuration of the system. Variable speed motor systemsconfigured for replacement of PSC motors in existing HVAC systems havebeen developed, but many have relatively complicated control and sensingsystems. For example, some systems require the installation of atemperature sensor in the outlet ductwork of the HVAC system forcontrolling the speed of the motor based upon temperature. Otherreplacement systems require the connection of low voltage controlsignals directly from the thermostat to the motor. Making theseconnections can be cumbersome and difficult in an existing HVAC system.Moreover, these known systems lack the sensitivity to operate blowers atlow operating speeds and do not benefit from the relays and controlfunctions in existing furnace control boards.

Still other replacement systems use the control functions of existingfurnace control boards but lack standby power when the furnace controlboard does not call for motor operation. This makes it impossible toprogram start and stop delays, ramp-down or ramp-up features, or othercontrol features directly into the variable speed motor.

It would therefore be desirable to provide an improved HVAC replacementmotor for a PSC motor to realize the advantages of a variable speedblower motor without requiring significant changes to the HVAC system.It would be further advantageous to reduce the complexity of suchreplacement systems by utilizing simple control circuits and eliminatingthe need for extensive additional wiring, such as that used inconjunction with traditional variable speed motors and existingreplacement variable speed motor systems. It would also be advantageousto provide an HVAC blower motor that could be more easily customizedwith start and stop delays, motor ramp-up speeds, and/or motor ramp-downspeeds.

SUMMARY

The present invention solves many of the above-described problems andother problems and provides a distinct advance in the art of HVAC blowermotors and other electric motors.

One embodiment of the invention is a blower motor assembly broadlycomprising a variable speed motor and motor controller; a first powerinput for receiving a plurality of AC power signals from a furnacecontrol board or other control device; and a second power input forreceiving AC power from an AC power source for powering the motorcontroller even when no AC power signals are received by the first powerinput.

The first power input may be used for determining an operating parameterfor the motor and comprises a number of individual power connections,each associated with one of the speed taps of a PSC motor being replacedby the blower motor assembly of the present invention. For example, whenthe blower motor assembly of the present invention is designed toreplace a two-speed/tap PSC motor, the first power input comprises twopower connections, one associated with a cooling mode of operation andthe other a heating mode of operation. A sensing circuit is coupled withthe first power input to determine which of the individual powerconnections is energized by the furnace control board. This allows themotor controller to determine the appropriate speed of the motor basedon existing control settings in the furnace control board.

The second power input, along with a neutral input, is connected to arectifier for providing AC power to the rectifier and the motor andmotor controller. The second power input may receive AC power from theline voltage applied to the input of the furnace control board or fromany other source or supply of power. Because the second power input doesnot receive its power from the output of the furnace control board, itprovides power to the motor and motor controller even when the furnacecontrol board and its associated thermostat are not calling for heating,cooling, or any other blower motor operation. This “standby” powerpermits an installer or other person to test, program, or otherwiseoperate the motor independently of the furnace control board. Forexample, with standby power, an installer may program start and stopdelays, start ramp-ups, and/or stop ramp-downs directly into the motorcontroller independently of the furnace control board.

By constructing a blower motor assembly as described herein, numerousadvantages are realized. For example, the blower motor assembly of thepresent invention can be used as a relatively low-cost replacement foran inefficient fixed speed motor in an existing HVAC system. Thereplacement blower motor assembly uses less energy, allows foreconomical continuous fan operation, and is quieter than conventionalfixed speed motors. Moreover, the blower motor assembly can be quicklyand easily installed without requiring extensive changes to themechanical configurations, wiring, or control of the HVAC system.

By using the speed/tap power signals from an existing furnace controlboard for control purposes, the blower motor assembly benefits from theexisting speed control relays and settings for an HVAC system. Thisallows the blower motor assembly to utilize any start and stop delaysalready programmed into the furnace control board. Moreover, byinclusion of a second power input for receiving power for the motor andmotor controller independently of the furnace control board, aninstaller or other person may test, program, or otherwise operate themotor even when the furnace control board does not call for motoroperation. This allows an installer to provide additional start and stopdelays and ramp-up and ramp-down cycles beyond those already programmedinto the furnace control board.

The blower motor assembly of the present invention may also be used inOEM and other non-replacement applications. Moreover, many aspects ofthe present invention may be separately useful without the motor, bothfor OEM and/or replacement use.

These and other important aspects of the present invention are describedmore fully in the detailed description below.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Embodiments of the current invention are described in detail below withreference to the attached drawing figures, wherein:

FIG. 1 is a schematic circuit diagram of a prior art blower motor andassociated control circuitry for an HVAC system.

FIG. 2 is a schematic circuit diagram of another prior art blower motorand associated control circuitry for an HVAC system.

FIG. 3 is a schematic circuit diagram of a blower motor assemblyconstructed in accordance with an embodiment of the invention and shownwired to associated control circuitry and power connections of an HVACsystem.

FIG. 4 is a schematic circuit diagram of an exemplary rectifier of theblower motor assembly shown in FIG. 3.

FIG. 5 is a schematic circuit diagram of the blower motor assembly ofFIG. 3 showing an embodiment of the sensing circuit in more detail.

FIG. 6 is a truth table representing a logic function of the motorcontroller for the sensing circuit of FIG. 5.

FIG. 7 is a flow diagram depicting a method of replacing a fixed speedmotor with a variable speed blower motor assembly such as the one shownin FIG. 3.

The drawing figures do not limit the present invention to the specificembodiments disclosed and described herein. The drawings are notnecessarily to scale, emphasis instead being placed upon clearlyillustrating the principles of the invention.

DETAILED DESCRIPTION

The following detailed description of the invention references theaccompanying drawings that illustrate specific embodiments in which theinvention can be practiced. The embodiments are intended to describeaspects of the invention in sufficient detail to enable those skilled inthe art to practice the invention. Other embodiments can be utilized andchanges can be made without departing from the scope of the presentinvention. The following detailed description is, therefore, not to betaken in a limiting sense. The scope of the present invention is definedonly by the appended claims, along with the full scope of equivalents towhich such claims are entitled.

In this description, references to “one embodiment”, “an embodiment”, or“embodiments” mean that the feature or features being referred to areincluded in at least one embodiment of the technology. Separatereferences to “one embodiment”, “an embodiment”, or “embodiments” inthis description do not necessarily refer to the same embodiment and arealso not mutually exclusive unless so stated and/or except as will bereadily apparent to those skilled in the art from the description. Forexample, a feature, structure, act, etc. described in one embodiment mayalso be included in other embodiments, but is not necessarily included.Thus, the current technology can include a variety of combinationsand/or integrations of the embodiments described herein.

Referring to FIG. 3, a blower motor assembly 10 constructed inaccordance with an embodiment of the invention is shown. The illustratedblower motor assembly 10 broadly comprises a variable speed motor 12,the motor's associated motor controller and power converter 14, arectifier 16, a first power input 18, a sensing circuit 20, and a secondpower input 22. The components of the blower motor assembly 10 may beinstalled or contained in a conventional motor housing or “can” or inany other enclosure.

As described in more detail below, the first power input 18 has severalindividual power connections for receiving speed/tap selection powersignals from a furnace control board 21 or other control device. Thesepower signals are used by the blower motor assembly 10 for controlpurposes to determine the appropriate speed of the motor 12.Advantageously, this provides motor speed selection, motor start andstop delays, and other control functions for the blower motor assembly10 based on existing control settings in the furnace control board 21.The second power input 22, along with a neutral input, is connected tothe rectifier 16 for providing AC power to the rectifier 16 and themotor 12 and motor controller 14 independently of the furnace controlboard 21. The second power input 22 provides power to the motor 12 andmotor controller 14 even when the furnace control board 21 and itsassociated thermostat are not calling for heating, cooling, or any otherblower motor operation. This “standby” power permits an installer orother person to test, program, or otherwise operate the motor 12independently of the furnace control board 21. For example, with standbypower, start and stop delays, start ramp-ups, and stop ramp-downs may beprogrammed directly into the motor controller 14 independently of thefurnace control board 21.

The blower motor assembly 10 can serve as a drop-in replacement, withthe provision of an extra line voltage power connection at the secondpower input 22, for that portion of the PSC motors of FIGS. 1 and 2enclosed by the rectangles 10A and 10B. The blower motor assembly 10 canalso be used in OEM and other non-replacement applications. Moreover,many aspects of the present invention may be separately useful withoutthe motor 12 and motor controller 14, both for OEM and/or replacementuse.

The motor 12 and motor controller 14 may be any conventional variablespeed motor and controller suitable for use in HVAC blower assembliesand other applications. For example, the motor may be a high efficiencypermanent magnet type motor between ⅓-1 HP and may be rated 115 or 230volt.

The rectifier 16 converts the AC power on the second power input 22 andneutral connection N to DC power and delivers the DC power to the motorcontroller 14. An embodiment of the rectifier 16 is shown in FIG. 4 andincludes a rectifier bridge comprising diodes D1, D2, D3, and D4.

The first power input 18 comprises a number of individual powerconnections for receiving 115V or 230V AC power signals from the furnacecontrol board 21 or other control device. The power connections maycomprise conventional electrical plugs, terminals, sockets, conductorsor any other device or mechanism capable of connecting to a wire, cable,or other electrical conductor. Each of the received power signals may beassociated with one of the speed taps of a PSC motor being replaced bythe blower motor assembly 10 of the present invention.

For example, when the blower motor assembly 10 is designed to replace atwo-speed/tap PSC motor (such as the one shown in FIG. 1), the firstpower input 18 comprises two power connections, one for receiving apower signal (L1C) from the furnace control board 21 associated with acooling mode of operation and the other for receiving a power signal(L1H) from the furnace control board associated with a heating mode ofoperation. Similarly, when the blower motor assembly 10 is designed toreplace a four-speed/tap PSC motor (such as the one shown in FIG. 2),the first power input 18 comprises four power connections for receivingfour power signals from the furnace control board 21 associated withhigh cool, low cool, high heat, and low heat modes of operation. In yetanother embodiment, the first power input 18 may have five powerconnections for receiving five different power signals corresponding toa highest blower speed, a medium-high blower speed, a medium blowerspeed, a medium-low blower speed, and a low blower speed. Still otherembodiments of the first power input may have other numbers of powerconnections. However, in all the embodiments, the first power input 18is configured for receiving 115V, 230V, or other power signals from thefurnace control board 21 or other control device. Some component valueswill be different for 230 volts.

FIG. 5 illustrates an embodiment of the sensing circuit 20 for a blowermotor assembly 10 configured to replace a five-speed/tap PSC motor. Theexemplary blower motor assembly of FIG. 5 includes a first power input18 b with five power connections IN1-IN5 and three opto couplercircuits, generally indicated as U1, U2, and U3, for sensingvoltage/current in the inputs IN1-IN5 and for providing associatedsignaling to the motor controller 14 for determining a corresponding fanspeed or other motor parameter. The output signals from U1, U2, and U3are indicated as a, b, and c. The sensing circuit 20 uses opto couplersto isolate the high input power voltage signals from the first powerinput 18 from the logic common and the motor controller 14 thatinterprets the signals coming out of the opto couplers.

The sensing circuit 20 also includes a voltage divider network for eachof the five input circuit taps. Each voltage divider network has aresistor R1, a resistor R2, and a shared resistor R3. In one embodiment,each R1 may be 1.5K ohm, each R2 may be 5.6K ohm, and R3 may be 6.2Kohm. Each R2 resistor has a capacitor C1 (may be 0.022 uf) across it fornoise reduction. Each R2-C1 network is shunted for the positive halfcycle of the line by a diode D1, a Zener D2, and the input LED D3 of anopto coupler U1, U2, or U3. As the positive half cycle of each lineincreases to a peak value, current will flow through the input LED D3 ofits opto coupler, causing an output transistor T1 to turn on and pulldown the a, b, or c input to the motor controller 14. Input circuits IN2and IN4 have to drive two opto inputs and have current sharing resistorsR4 (may be 510 ohm) to assure that both optos get equal input current tobe sure they both turn on.

The motor controller 14 detects the a, b, or c inputs being pulled lowfor parts of each line cycle to determine that the input is activerather than inactive. For inactive, the input is stuck at the +Vccvoltage for the motor controller 14, which is typically 3.3 or 5 voltsdc.

The motor controller 14 then evaluates which inputs a, b, and/or c areactive to decide at which speed or torque value to run the motor 12. Assoon as it sees an input go active, it will start the motor 12 and rampit to that operating speed or torque value saved in the motor controller14 for that input. When the inputs change, the motor controller 14 willramp to the new operating speed. If all of the inputs go to an inactivecondition, the motor controller 14 will ramp the motor 12 down to a lowspeed and stop the motor. If a delay on stopping is called for, themotor controller 14 will continue to operate until the stop delay hastimed out and then ramps down and stops.

The power inputs IN1-IN5 may correspond to any set of operatingparameters for the motor 12. In one exemplary embodiment, IN1 maycorrespond to a highest blower speed (e.g. 100% speed), IN2 maycorrespond to a medium/high blower speed (e.g. 90% speed), IN3 maycorrespond to a medium blower speed (e.g. 80% speed), IN4 may correspondto a medium/low blower speed (e.g. 70% speed), and IN5 may correspond toa low blower speed (e.g. 60% speed).

As described above, the motor controller 14 receives signals a, b, and cfrom the sensing circuit 20 and determines a motor speed or other motorparameter based on a combination of the signals. FIG. 6 shows anexemplary truth table that may be utilized by the motor controller 14 todetermine a motor operating speed or other motor parameter based on thesensing of current in IN1-IN5. The first line of the truth table showsthat none of the opto couplers U1, U2, or U3 sensed current/voltage (“X”denotes sensing of current/voltage) in any of the power inputs so themotor should be stopped. The second line of the truth table shows thatopto coupler U1 sensed current/voltage but opto couplers U2 and U3 didnot. This indicates that only power input IN1 was energized because ifany of IN2-IN5 inputs were also energized, opto couplers U2 or U3 alsowould have sensed current/voltage. The motor controller 14 thereforedetermines that a motor speed or other motor parameter (e.g., torque,power, airflow) associated with input IN1 is appropriate. For example,if input IN1 corresponds to the highest speed tap of the replaced PSCmotor M1, the motor controller 14 may operate the variable speed motor12 at a maximum speed.

The third line of the truth table shows that opto couplers U1 and U2both sensed current/voltage but opto coupler U3 did not. This indicatesthat power input IN2 was energized because it is the only power inputsensed by both opto couplers U1 and U2. The motor controller 14therefore determines a motor speed or other parameter associated withIN2. The fourth line of the truth table shows that only opto coupler U2sensed current/voltage, thus indicating that power input IN3 wasenergized because only IN3 is monitored solely by opto coupler U2 alone.The motor controller 14 therefore determines a motor speed or othermotor parameter associated with IN3. The fifth line of the truth tableshows that opto couplers U2 and U3 sensed current/voltage, thusindicating that power input IN4 was energized because only it is sensedby both these opto couplers. The motor controller 14 thereforedetermines a motor speed or other motor parameter associated with IN4.The sixth line of the truth table shows that only opto coupler U3 sensedcurrent/voltage, thus indicating that power input IN5 was energized,because IN5 is the only power input sensed solely by this opto coupleralone. The motor controller 14 b therefore determines a motor speed orother motor parameter associated with IN5.

Returning to FIG. 3, the second power input 22, along with a neutralinput is connected to the rectifier 16 for providing AC power to therectifier 16, the motor 12, and motor controller 14. The second powerinput 22 may comprise any conventional electrical plug, terminal,socket, conductor, or other device or mechanism capable of connecting toa wire, cable, or other conductor. The second power input may receive ACpower from the L1 connection to the furnace control board 21 asillustrated in FIG. 3 or from any other source or supply of livevoltage. Because the second power input 22 does not receive its powerfrom the output of the furnace control board 21, it provides power tothe motor 12 and motor controller 14 even when the furnace control board21 and its associated thermostat are not calling for heating, cooling,or any other blower motor operation. This “standby” power permits aninstaller or other person to test, program, or otherwise operate themotor 12 independently of the furnace control board 21. For example,with standby power, start and stop delays, start ramp-ups and stopramp-downs may be programmed directly into the motor controllerindependently of the furnace control board. Because the controller has astandby mode, it is possible for the motor to continue running after theinput signals have gone away for delay times such as 30, 60, or 90seconds, that would allow the system to extract the remaining heating orcooling from the heat exchanger before stopping the motor. These aretypical delay times in these applications.

FIG. 7 illustrates a method 700 of replacing a fixed speed motor with avariable speed motor assembly such as the blower motor assembly 10 shownin FIG. 3. The method first comprises the step of removing the permanentsplit capacitor motor as shown in step 702 of FIG. 7. This may be donein any conventional manner. The installer then installs the replacementmotor assembly by first connecting speed/tap selection wires from thefurnace control board 21 or other control device to the first powerinput 18 on the variable speed motor as depicted in step 704. Asmentioned above, these power connections from the furnace control board21 are used for control purposes to determine a speed setting of thevariable speed motor. The installer then connects an AC power line tothe second power input 22 on the variable speed motor as depicted instep 706 for powering the variable speed motor independently of thefurnace control board 21. The installer may then program speedcharacteristics directly into a motor controller 14 of the variablespeed motor 12 independently of any speed settings provided by thefurnace control board 21 as depicted in step 708. The speedcharacteristics may comprise start delays, stop delays, start ramp-ups,or stop ramp-downs.

Although the invention has been described with reference to theembodiments illustrated in the attached drawing figures, it is notedthat equivalents may be employed and substitutions made herein withoutdeparting from the scope of the invention as recited in the claims. Forexample, while the invention has been described in connection with 115VAC distribution systems, it is not limited to 115 VAC distributionsystems. One skilled in the art will recognize that, with obviousmodifications of implementation details, the invention may be adapted toother power distribution systems and voltages in use in the UnitedStates and elsewhere, including, but not limited to, 230 VACdistribution systems. Further, although many aspects of the presentinvention are particularly applicable to HVAC blower motors, they mayalso be used with electric motors designed for other applications.Moreover, all of the above-described embodiments of the invention areindependent of motor technology, and induction, brushless permanentmagnet, switched reluctance, brushed DC, and other types of motors maybe used. The invention is also compatible with a variety of convertertopologies, both for AC to DC and AC to AC conversion, including phasecontrol using a thyristor full converter or semiconverter. Relatedtechnologies are also disclosed in U.S. Pat. No. 5,818,194, which ishereby incorporated by reference in its entirety.

Having thus described the exemplary embodiment of the invention, what isclaimed as new and desired to be protected by Letters Patent includesthe following:
 1. A method of replacing a permanent split capacitormotor with a variable speed motor assembly including a variable speedmotor, the method comprising: removing the permanent split capacitormotor; connecting speed/tap selection wires from a furnace control boardto a sensing circuit of the variable speed motor assembly; connecting anAC power line to a rectifier circuit of the variable speed motorassembly for powering the variable speed motor independently of thefurnace control board; and programming start delays directly into amotor controller of the variable speed motor independently of any speedsettings provided by the furnace control board.
 2. The method of claim1, wherein the speed/tap selection wires are used for determining aspeed setting of the variable speed motor.
 3. The method of claim 1,further comprising: programming speed characteristics directly into amotor controller of the variable speed motor independently of any speedsettings provided by the furnace control board.
 4. The method of claim1, further comprising: programming stop delays directly into a motorcontroller of the variable speed motor independently of any speedsettings provided by the furnace control board.
 5. The method of claim1, further comprising: programming start ramp-ups directly into a motorcontroller of the variable speed motor independently of any speedsettings provided by the furnace control board.
 6. The method of claim1, further comprising: programming stop ramp-downs directly into a motorcontroller of the variable speed motor independently of any speedsettings provided by the furnace control board.
 7. A method of replacinga permanent split capacitor motor with a variable speed motor assemblyincluding a variable speed motor, the method comprising: removing thepermanent split capacitor motor; connecting speed/tap selection wiresfrom a furnace control board to a sensing circuit of the variable speedmotor assembly; connecting an AC power line to a rectifier circuit ofthe variable speed motor assembly for powering the variable speed motorindependently of the furnace control board; and programming start delaysand stop delays directly into a motor controller of the variable speedmotor independently of any speed settings provided by the furnacecontrol board.
 8. The method of claim 7, wherein the speed/tap selectionwires are used for determining a speed setting of the variable speedmotor.
 9. The method of claim 7, further comprising: programming startramp-ups directly into a motor controller of the variable speed motorindependently of any speed settings provided by the furnace controlboard.
 10. The method of claim 7, further comprising: programming stopramp-downs directly into a motor controller of the variable speed motorindependently of any speed settings provided by the furnace controlboard.
 11. A method of replacing a permanent split capacitor motor witha variable speed motor assembly including a variable speed motor, themethod comprising: removing the permanent split capacitor motor;connecting speed/tap selection wires from a furnace control board to asensing circuit of the variable speed motor assembly; connecting an ACpower line to a rectifier circuit of the variable speed motor assemblyfor powering the variable speed motor independently of the furnacecontrol board; and programming start ramp-ups and stop ramp-downsdirectly into a motor controller of the variable speed motorindependently of any speed settings provided by the furnace controlboard.
 12. The method of claim 11, wherein the speed/tap selection wiresare used for determining a speed setting of the variable speed motor.13. The method of claim 11, further comprising: programming start delaysdirectly into a motor controller of the variable speed motorindependently of any speed settings provided by the furnace controlboard.
 14. The method of claim 11, further comprising: programming stopdelays directly into a motor controller of the variable speed motorindependently of any speed settings provided by the furnace controlboard.
 15. A method of replacing a permanent split capacitor motor witha variable speed motor assembly including a variable speed motor, themethod comprising: removing the permanent split capacitor motor;connecting speed/tap selection wires from a furnace control board to asensing circuit of the variable speed motor assembly; connecting an ACpower line to a rectifier circuit of the variable speed motor assemblyfor powering the variable speed motor independently of the furnacecontrol board; and programming stop delays directly into a motorcontroller of the variable speed motor independently of any speedsettings provided by the furnace control board.
 16. A method ofreplacing a permanent split capacitor motor with a variable speed motorassembly including a variable speed motor, the method comprising:removing the permanent split capacitor motor; connecting speed/tapselection wires from a furnace control board to a sensing circuit of thevariable speed motor assembly; connecting an AC power line to arectifier circuit of the variable speed motor assembly for powering thevariable speed motor independently of the furnace control board; andprogramming start ramp-ups directly into a motor controller of thevariable speed motor independently of any speed settings provided by thefurnace control board.
 17. A method of replacing a permanent splitcapacitor motor with a variable speed motor assembly including avariable speed motor, the method comprising: removing the permanentsplit capacitor motor; connecting speed/tap selection wires from afurnace control board to a sensing circuit of the variable speed motorassembly; connecting an AC power line to a rectifier circuit of thevariable speed motor assembly for powering the variable speed motorindependently of the furnace control board; and programming stopramp-downs directly into a motor controller of the variable speed motorindependently of any speed settings provided by the furnace controlboard.